I have a 2004 F-150 FX4 Supercab with the 5.4L and just shy of 68,000 miles. For the last year, I've had a ticking noise coming from my motor. I assumed that it was the manifold because the Fords are known for the studs breaking off and causing that problem. Additionally, I had put on an aftermarket exhaust just prior to that noise beginning, so I assumed that it was related. Now that its gotten colder out with the onset of winter, the noise is louder and definitely sounds like a lifter issue. When I'm sitting inside my truck, it almost sounds like a diesel motor. As the engine gets to normal operating temperatures, that ticking noise quiets down, but is still very noticeable.

Since brand new, this truck has been run with Castrol Syntec full synthetic 5W-20 oil, and I have used the K&N Oil filter. I have changed the oil every 5,000 miles.

I tried to add some Lucas Engine Treatment to see if it would reduce the knocking noise. When I checked the oil level, it was only at half of what it should have been. In the past, when I checked the oil level, it was always at full. I have only driven the truck 1500 miles since changing the oil last. Also, when I took off the oil cap, I found that yellow cottage cheese type stuff all over the inside of the cap, and down the oil tube as well. This would mean that there is air/moisture getting into the oil. When I smelled the sludge/cottage cheese, I found that it smelled more like gasoline, and not like oil. This would mean that somehow the gasoline is leaking from the cylinder and getting in with the oil.

I added the engine treatment and the noise did not stop. I have been keeping an eye on my antifreeze level and that hasn't changed. I had the radiator pressure checked and everything was normal. Also, the coolant does not look like whipped cream, which is definitely a good thing.

I took the truck to my local Ford dealer to have them investigate the noise, and Ford says that it is coming from underneath the valve covers. I then took the truck to my own mechanic, and he checked it out and says that there is definitely a strong knock coming from the bottom of the motor. There is definitely a lifter issue, but there must be something else that would cause the fuel to get into the oil.

He recommended that before I do anything, I try changing my oil to either conventional or synthetic blend and to change the grade from 5w-20 to 10w-30, and use a different oil filter. He said that because the fuel is getting into the oil, it is thinning the oil out and causing it to not lubricate the engine properly. Thus, he said this might better lubricate the motor, thereby stopping that knocking noise and preventing fuel leak from the motor.

Is there any merit to that?

He then said that if that does not stop the noise, then he will give me an estimate in cost to rip apart the motor and look at every single part of it to determine what the problem might be. I'm worried though about spending a ton of money just to have the problem diagnosed. And then possibly spending an additional ton of money to have it repaired. I am aware that it is generally impossible to know what is internally wrong with a motor unless you rip it apart to find out. It could be anything, realistically. I'm pissed off and annoyed that the truck only has 68k miles on it and might potentially need major engine work. I've been a Ford owner for many years and owned many different Fords and never had a problem such as this. I am quite disappointed.

Any help would be appreciated. Thanks.

 

When does the noise occur hot or cold I have 04 fx4 and the 5.4 and4.6 are know for bad cam phasers and lifters. If it only does it hot sounds like cam phasers. Its not to bad of a job with the right tools. Do some research if that sounds like your problem.

 

mine truck knocks too and when i changed my oil i seen the yellow cheese like stuff on my fill cap as well it also smelt like gas. i think its an air/moisture issue make sure that the dip stick o-ring isnt messed up and it is pushed down hard. mine wasnt all the way down from when i last checked it. it could also be the cap itself letting air in. i wouldnt worry about it untill the oil in the pan is messed up. my forklift at work has had a problem with the dipstick and still runs strong. hope this helps

 

Well it seems as if my problems have been solved rather unfortunately. I went to start my truck and the noise was much louder all of a sudden. Additionally the engine ran like **** and rough idled. Had it towed to Ford and they ended up finding that it was a bad cam shaft. Cost me over $2000 to fix. Very disappointed considering that truck was babied and never beaten or abused. Bad taste in my mouth left by this truck..

 

thats very unfortunate especially that the truck was run under normal if not less than operating conditions. i hope my engine doesnt have any major mechanical problems....knock on wood

 

My 04 knocks and I know some of it is the cam phasers as well. However, like you said, I hear a knock that sounds like it is coming from the bottom end when the truck is warmed up. When it is cold, I hear nothing. I dont really want to address the phaser issue if something in the bottom end is wrong. My truck runs smooth for the most part, no codes, on 70k. Did your knock in the bottom end go away after everything was repaired? Anyone else know if it was a bad thrust bearing would it knock cold and hot or just hot?

 

The knock was gone once the camshaft was replaced. Everything now appears to be OK with it.